Kawasaki Super Sherpa Kl250g9 Owners Manual

Quick Reference Guide
This Quick Reference Guide will

assist you in finding the information
youre looking for.
A Table of Contents is included after

the Foreword.
GENERAL INFORMATION
HOW TO RIDE THE MOTORCYCLE
SAFE OPERATION
MAINTENANCE AND ADJUSTMENT
STORAGE
TROUBLESHOOTING GUIDE
Whenever you see the symbols

shown below, heed their instructions!
Always follow safe operating and maintenance practices.
WARNING
This warning symbol identifies
special instructions or procedures which, if not correctly followed, could result in personal
injury, or loss of life.
CAUTION
This caution symbol identifies
special instructions or procedures which, if not strictly observed, could result in damage
to or destruction of equipment.
NOTE
This note symbol indicates points of

particular interest for more efficient
and convenient operation.
FOREWORD
Congratulations on your purchase of a new Kawasaki motorcycle. Your new motorcycle is the product of Kawasakis advanced engineering, exhaustive testing,
and continuous striving for superior reliability, safety and performance.
Please read this Owners Manual carefully before riding so that you will be
thoroughly familiar with the proper operation of your motorcycles controls, its features, capabilities, and limitations. This manual offers many safe riding tips, but its
purpose is not to provide instruction in all the techniques and skills required to ride
a motorcycle safely. Kawasaki strongly recommends that all operators of this vehicle enroll in a motorcycle rider training program to attain awareness of the mental
and physical requirements necessary for safe motorcycle operation.
To ensure a long, trouble-free life for your motorcycle, give it the proper care and
maintenance described in this manual. For those who would like more detailed information on their Kawasaki Motorcycle, a Service Manual is available for purchase
from any authorized Kawasaki motorcycle dealer. The Service Manual contains detailed disassembly and maintenance information. Those who plan to do their own
work should, of course, be competent mechanics and possess the special tools
described in the Service Manual.
Keep this Owners Manual aboard your motorcycle at all times so that you can
refer to it whenever you need information.
This manual should be considered a permanent part of the motorcycle and should
remain with the motorcycle when it is sold.
All rights reserved. No part of this publication may be reproduced without our
prior written permission.
This publication includes the latest information available at the time of printing.
However, there may be minor differences between the actual product and illustrations and text in this manual.
All products are subject to change without prior notice or obligation.
KAWASAKI HEAVY INDUSTRIES, LTD.

Consumer Products & Machinery Company
2008 Kawasaki Heavy Industries, Ltd.
Nov. 2008. (1). (S, Ke)
TABLE OF CONTENTS
SPECIFICATIONS...............................
SERIAL NUMBER LOCATIONS.........
LOCATION OF PARTS .......................
LOCATION OF LABELS.....................
LOADING INFORMATION..................
GENERAL INFORMATION.................
Meter Instruments ............................
Speedometer, Odometer/Clock,
and Trip Meter: ..........................
Speedometer : ..............................
Indicator Lights: ............................
Key ...................................................
Ignition Switch/Steering Lock ...........
Right Handlebar Switches................
Engine Stop Switch: .....................
Starter Button: ..............................
Left Handlebar Switches ..................
Dimmer Switch: ............................
Turn Signal Switch:.......................
Horn Button: .................................
8
12
13
16
19
22
22
23
23
26
27
28
29
29
30
31
31
31
31
Fuel Tank Cap ..................................

Fuel Tank .........................................
Fuel Requirement: ........................
Fuel Tap ...........................................
Stand................................................
Helmet Hook ....................................
Tool Kit Case/Tool Kit .......................
Side Cover .......................................
Seat..................................................
BREAK-IN ...........................................
HOW TO RIDE THE MOTORCYCLE .
Starting the Engine ..........................
Jump Starting ...................................
Moving Off........................................
Shifting Gears ..................................
Braking .............................................
Stopping the Engine.........................
Stopping the Motorcycle in an
Emergency ...................................
Parking .............................................
32
33
34
37
38
39
40
41
43
44
46
46
50
52
53
55
56
57
58
SAFE OPERATION.............................
Safe Riding Technique .....................
Daily Safety Checks .........................
Additional Considerations for Off
Road Operation ............................
Periodic Maintenance Chart.............
Engine Oil ........................................
Spark Plugs......................................
Valve Clearance ...............................
Air Cleaner .......................................
Throttle Grip .....................................
Carburetors ......................................
Clutch ...............................................
Drive Chain ......................................
Brakes ..............................................
59
59
61
63
64
69
80
85
87
87
91
94
95
98
103
Brake Light Switches........................

Rear Shock Absorber.......................
Wheels .............................................
Battery..............................................
Headlight Beam................................
Fuses ...............................................
General Lubrication..........................
Cleaning Your Motorcycle ................
Bolt and Nut Tightening....................
STORAGE...........................................
TROUBLESHOOTING GUIDE............
OWNER SATISFACTION....................
REPORTING SAFETY DEFECTS ......
ENVIRONMENTAL PROTECTION.....
MAINTENANCE RECORD .................
LABEL INFORMATION ......................
108
110
112
115
117
119
121
122
127
129
133
134
136
137
138
143
8 SPECIFICATIONS
SPECIFICATIONS
DIMENSIONS
Overall Length
2 080 mm (81.89 in.)
Overall Width
780 mm (30.71 in.)
Overall Height
1 190 mm (46.85 in.)
Wheelbase
1 375 mm (54.13 in.)
Road Clearance
270 mm (10.63 in.)
Curb Mass
128 kg (282 lb)
ENGINE
Type
DOHC, single-cylinder, 4-stroke, air-cooled
Displacement
249 cm (15.2 cu in.)
Bore x Stroke
72.0 61.2 mm (2.83 2.41 in.)
Compression Ratio
9.3 : 1
Starting System
Electric starter
Carburetors
MIKUNI BST34
Ignition System
CDI
SPECIFICATIONS 9
Ignition Timing
(Electronically advanced)
10 BTDC @1 300 r/min (rpm) 30 BTDC @5 750

r/min (rpm)
Spark Plugs
NGK CR8E or ND U24ESR-N
Lubrication System
Forced lubrication (wet sump)
Engine Oil
Type:
API SE, SF or SG
API SH, SJ, SL or SM with JASO MA, MA1 or MA2
SAE 10W-40
Capacity:
1.5 L (1.6 US qt)
TRANSMISSION
Transmission Type
6-speed, return shift
Clutch Type
Wet, multi disc
Driving System
Chain drive
Primary Reduction Ratio
2.800 (84/30)
Final Reduction Ratio
3.071 (43/14)
Overall Drive Ratio
7.326 (Top gear)
10 SPECIFICATIONS
Gear Ratio
1st
3.090 (34/11)
2nd
2.125 (34/16)
3rd
1.500 (27/18)
4th
1.148 (31/27)
5th
0.962 (25/26)
6th
0.852 (23/27)
FRAME
Castor
28
Trail
107 mm (4.21 in.)
Tire Size:
Front
2.75-21 45P
Rear
4.10-18 59P
Rim Size:
Front
Rear
Fuel Tank Capacity
21 1.60
18 2.15
9.0 L (2.38 US gal)
SPECIFICATIONS 11
ELECTRICAL EQUIPMENT
Battery
12 V 6 Ah
Headlight
12 V 60/55 W
Tail/Brake Light
12 V 5/21 W
Specifications subject to change without notice.
12 SERIAL NUMBER LOCATIONS
SERIAL NUMBER LOCATIONS

The engine and frame serial numbers are used to register the motorcycle. They
are the only means of identifying your particular machine from others of the same
model type. These serial numbers may be needed by your dealer when ordering
parts. In the event of theft, the investigating authorities will require both numbers
as well as the model type and any peculiar features of your machine that can help
them identify it.
Frame No.
A. Frame Number
Engine No.
A. Engine Number
LOCATION OF PARTS 13
LOCATION OF PARTS
1.
2.
3.
4.
5.
Clutch Lever
Meter Instruments
Choke Knob
Brake Fluid Reservoir (Front)
Front Brake Lever
6.
7.
8.
9.
Left Handlebar Switches

Ignition Switch/Steering Lock
Right Handlebar Switches
Throttle Grip
14 LOCATION OF PARTS
10.
11.
12.
13.
14.
15.
Front Fork
Headlight
Turn Signal Light
Fuel Tank Cap
Fuel Tank
Fuel Tap
16.
17.
18.
19.
20.
21.
Rear Shock Absorber

Battery
Helmet Hook
Tool Kit Case/Tool Kit
Brake Disc
Brake Caliper
22.
23.
24.
25.
26.
Shift Pedal
Idle Adjusting Screw
Side Cover
Side Stand
Drive Chain
LOCATION OF PARTS 15
27.
28.
29.
30.
31.
Tail/Brake Light
Muffler
Air Cleaner Element
Seat
Front Brake Light
Switch
32. Brake Fluid Reservoir

(Rear)
33. Rear Brake Light
Switch
34. Rear Brake Pedal
35. Oil Level Gauge
36. Carburetor
16 LOCATION OF LABELS
LOCATION OF LABELS
1.
2.
3.
4.
5.
Important Break-In Instructions

Tire and Load Data
Important Drive Chain Information
Vehicle Emission Control Information
Daily Safety Checks
(For further information of label,
refer to the LABEL INFORMATION
chapter.)
LOCATION OF LABELS 17
6.
7.
8.
9.
Battery Poison/Danger
Engine Oil and Oil Filter
Brake Fluid (Rear)
Brake Fluid (Front)
chapter.)
18 LOCATION OF LABELS
10. Noise Emission Control Information

11. Weight and Manufacture
chapter.)
LOADING INFORMATION 19
LOADING INFORMATION
WARNING
Incorrect loading, improper installation or use of accessories,
or modification of your motorcycle may result in an unsafe riding condition. Before you ride
the motorcycle, make sure that
the motorcycle is not overloaded
and that you have followed these
instructions.
With the exception of genuine
Kawasaki Parts and Accessories,
Kawasaki has no control over the
design or application of accessories.
In some cases, improper installation
or use of accessories, or motorcycle
modification, will void the motorcycle
warranty. In selecting and using accessories, and in loading the motorcycle,

you are personally responsible for your
own safety and the safety of other persons involved.
NOTE
Kawasaki
Parts and Accessories

have been specially designed for
use on Kawasaki motorcycles. We
strongly recommend that all parts
and accessories you add to your
motorcycle be genuine Kawasaki
components.
Because a motorcycle is sensitive to

changes in weight and aerodynamic
forces, you must take extreme care
in carrying cargo, passengers and/or
in the fitting of additional accessories.
20 LOADING INFORMATION
The following general guidelines have

been prepared to assist you in making
your determinations.
1. Any passenger should be thoroughly familiar with motorcycle operation. The passenger can affect
control of the motorcycle by improper positioning during cornering
and sudden movements. It is important that the passenger sit still while
the motorcycle is in motion and not
interfere with the operation of the
motorcycle. Do not carry animals
on your motorcycle.
2. You should instruct any passenger
before riding to keep his feet on the
passenger footpegs and hold on to
the operator grab rail. Do not carry
a passenger unless he or she is tall
enough to reach the footpegs and
footpegs are provided.
3. All baggage should be carried as

low as possible to reduce the effect
on the motorcycle center of gravity.
Baggage weight should also be distributed equally on both sides of the
motorcycle. Avoid carrying baggage
that extends beyond the rear of the
motorcycle.
4. Baggage should be securely attached. Make sure that the baggage
will not move around while you are
riding. Recheck baggage security
as often as possible (not while the
motorcycle is in motion) and adjust
as necessary.
5. Do not carry heavy or bulky items on
a luggage rack. They are designed
for light items, and overloading can
affect handling due to changes in
weight distribution and aerodynamic
forces.
LOADING INFORMATION 21
6. Do not install accessories or carry

baggage that impairs the performance of the motorcycle. Make
sure that you have not adversely
affected any lighting components,
road clearance, banking capability
(i.e., lean angle), control operation,
wheel travel, front fork movement,
or any other aspect of the motorcycles operation.
7. Weight attached to the handlebar or
front fork will increase the mass of
the steering assembly and can result in an unsafe riding condition.
8. Fairings, windshields, backrests,
and other large items have the capability of adversely affecting stability and handling of the motorcycle,
not only because of their weight, but
also due to the aerodynamic forces
acting on these surfaces while the
motorcycle is in operation. Poorly
designed or installed items can result in an unsafe riding condition.

9. This motorcycle was not intended
to be equipped with a sidecar or to
be used to tow any trailer or other
vehicle. Kawasaki does not manufacture sidecars or trailers for motorcycles and cannot predict the effects of such accessories on handling or stability, but can only warn
that the effects can be adverse and
that Kawasaki cannot assume responsibility for the results of such
unintended use of the motorcycle.
Furthermore, any adverse effects on
motorcycle components caused by
the use of such accessories will not
be remedied under warranty.
Maximum Load
Weight of rider, passenger, baggage,
and accessories must not exceed 165 kg
(364 lb).
22 GENERAL INFORMATION
GENERAL INFORMATION
Meter Instruments
A.
B.
C.
D.
Speedometer
Odometer/Clock
Twin Trip Meter
Odometer/Clock Mode
Button
E. Trip A/B Mode Button
F. Neutral Indicator Light
G. Turn Signal Indicator Light
H. High Beam Indicator Light
GENERAL INFORMATION 23
Speedometer, Odometer/Clock, and

Trip Meter:
In the meter instruments face are
the LCD (Liquid Crystal Display)
speedometer, odometer/clock and trip
meter. Pushing the odometer/clock
(ODO/CLOCK) mode button shifts the
display in the odometer/clock through
the two modes; odometer and clock.
Pushing the trip meter A/B (TRIP A/B)
mode button shifts the display in the
trip meter through the two modes; trip
A and B. When the ignition switch is
turned on, all the LCD segments are
displayed for three seconds, then the
clock or meters operate normally depending on the mode selected.
Odometer The odometer shows the total distance in kilometers that the vehicle has
been ridden. The meter cannot be reset.
Speedometer :
The speedometer shows the speed
of the vehicle.
Clock:
To adjust hours and minutes:
Turn the ignition key to ON.
Push the ODO/CLOCK button, and
display the clock.
NOTE
The data is maintained even if the

battery is disconnected.
When the figures come to 99999,
they are stopped and locked.
the TRIP A/B button with the

Push
ODO/CLOCK button pushed in. Both
the ODO/CLOCK button. The

Push
hour display stops flashing and the
the hour and minute displays start

flashing.
minute display starts flashing. And

push the TRIP A/B button to advance
the minutes.
push the ODO/CLOCK button,

Again
then the hour display only flashes.
And push the TRIP A/B button to advance the hours.
the ODO/CLOCK button. Both

Push
the hour and minute displays start
flashing again.
Push the TRIP A/B button. The display stop flashing and the clock starts
working.
NOTE
Pushing
the TRIP A/B button momentarily advances the hour or

minute step by step. Pushing and
holding the button advance the hour
or minute continuously.
The clock works normally from the
back-up power while the ignition
switch is turned off.
When the battery is disconnected,
the clock resets to 1:00 and starts
working again when the battery is
connected.
Trip Meters A/B The trip meter shows the distance in
kilometers traveled since it was last reset to zero.
TRIP A: 0.0 999.9
TRIP B: 0 9999
To reset the trip meter:
the TRIP A/B button and hold it

Push
in.
two second, the figure display
After
turns to 0.0 (TRIP A) or 0 (TRIP B),
and then starts counting when the vehicle is operated. The meter counts
until it is next reset.
NOTE
The data is maintained by the back
-up power if the ignition key is turned

to OFF
When the trip meter is reset while the
vehicle is stopped, it starts counting
as soon as the vehicle starts moving.
When the figures come to 999.9
(TRIP A) or 9999 (TRIP B) when the
vehicle is running, they turn back to
0.0 and start counting again.
When the battery is disconnected,
the meter display resets to 0.0 or 0.
: When the headlight is on high

beam, the high beam indicator light is
lit.
Indicator Lights:
N : When the transmission is in neutral,
the neutral indicator light is lit.
: When the turn signal switch is
turned to left or right, the turn signal
indicator light flashes on and off.
Key
This motorcycle has a combination
key, which is used for the ignition
switch/steering lock, helmet hook, and
fuel tank cap.
Blank keys are available at your
Kawasaki dealers. Ask your dealer to
make any additional spare keys you
may need, using your original key as
a master, or using the key code on the
tag with your keys.
Record the code on the tag with your
keys here.
Participating Kawasaki
dealers can use the code to make a
new key in the event that your original
keys are lost.
Write your key number here.
Ignition Switch/Steering Lock

This is a four-position, key-operated
switch. The key can be removed from
the switch when it is in the OFF, LOCK,
or P (Park) position.
ON
Engine on. All electrical

equipment can be used.
OFF
Engine off. All electrical

circuits off.
LOCK
Steering locked. Engine off.

All electrical circuits off.
Steering locked. Engine off.

P (Park) Taillight on. All other electrical
circuits cut off.
NOTE
The
A. Ignition Switch/Steering Lock
B. ON position
C. OFF position
D. LOCK position
E. P (Park) position
headlight and taillight are on

whenever the ignition key is in the
ON position. To avoid battery discharge, always start the engine immediately after turning the ignition
key to "ON".
If you leave the P (Park) position on
for a long time (one hour), the battery
may become totally discharged.
To lock the steering:

1. Turn the handlebar fully to the left.
2. With the ignition key in the OFF position, push down and release the key.
3. Turn the key to LOCK or P (Park)
position.
4. Pull the key out.
NOTE
If the steering is hard to lock, turn the

handlebar slightly to the left or the
right.
Right Handlebar Switches

Engine Stop Switch:
In addition to the ignition switch, the
engine stop switch must be in the RUN
position (RUN switch pushed in) for the
motorcycle to operate.
The engine stop switch is for emergency use. If some emergency requires stopping the engine, push the
engine stop switch to the OFF position
(OFF switch pushed in).
NOTE
Although the engine stop switch

stops the engine, it does not turn off
all the electrical circuits. Ordinarily,
the ignition switch should be used to
stop the engine.
Refer to the Starting the Engine section of the "How to Ride the Motorcycle"
chapter for starting instructions.
A.
B.
C.
D.
Engine Stop Switch

RUN Switch
OFF Switch
Starter Button
Starter Button:
The starter button operates the electric starter when pushed with the clutch
lever pulled in or the transmission is in
neutral.
Left Handlebar Switches

Dimmer Switch:
High or low beam can be selected
with the dimmer switch. When the
headlight is on high beam (HI), the
high beam indicator light is lit.
A. Dimmer Switch
B. Turn Signal Switch
C. Horn Button
Turn Signal Switch:

When the turn signal switch is turned
to L (left) or R (right), the corresponding
turn signals flash on and off.
To stop flashing, push the switch in.
Horn Button:
When the horn button is pushed, the
horn sounds.
Fuel Tank Cap

To open the fuel tank cap, insert the
ignition key into the fuel tank cap, turn
the key to the right.
To close the cap, push it down into
place with the key inserted. The key
can be removed by turning it to the left
to the original position.
A. Ignition Key
B. Fuel Tank Cap
NOTE
The fuel tank cap cannot be closed

without the key inserted, and the key
cannot be removed unless the cap is
locked properly.
Do not push on the key to close the
cap, or the cap cannot be locked.
Fuel Tank
The following octane rating gasoline
is recommended in the fuel tank. Avoid
filling the tank in the rain or where
heavy dust is blowing so that the fuel
does not get contaminated.
A.
B.
C.
D.
Tank Cap
Fuel Tank
Top Level
Filler Neck
WARNING
Gasoline is extremely flammable
and can be explosive under certain conditions. Turn the ignition key to "OFF". Do not smoke.
Make sure the area is well ventilated and free from any source
of flame or sparks; this includes
any appliance with a pilot light.
Never fill the tank so the fuel
level rises into the filler neck. If
the tank is overfilled, heat may
cause the fuel to expand and
overflow through the vents in
the tank cap.
After refueling, make sure the
fuel tank cap is closed securely.
If gasoline is spilled on the fuel
tank, wipe it off immediately.
CAUTION
Fuel Requirement:
Fuel Type
Use clean, fresh unleaded gasoline
with a minimum Antiknock Index of 87.
The Antiknock Index is posted on service station pumps. The octane rating
of a gasoline is a measure of its resistance to detonation or "knocking." The
Antiknock Index is an average of the
Research Octane Number (RON) and
the Motor Octane Number (MON) as
shown in the table.
Octane Rating Method
Antiknock
Index
(RON + MON)
2
Minimum
Rating
If engine "knocking" or "pinging" occurs, use a different

brand of gasoline of a higher
octane rating. If this condition is
allowed to continue it can lead
to severe engine damage.
Gasoline quality is important.
Fuels of low quality or not meeting standard industry specifications may result in unsatisfactory performance. Operating
problems that result from the
use of poor quality or nonrecommended fuel may not be covered
under your warranty.
87
Fuels Containing Oxygenates

Gasoline frequently contains oxygenates (alcohols and ethers) especially in areas of the U.S. and Canada
which are required to sell such reformulated fuels as part of a strategy to

reduce exhaust emissions.
The types and volume of fuel oxygenates approved for use in unleaded
gasoline by the U.S. Environmental
Protection Agency include a broad
range of alcohols and ethers, but only
two components have seen any significant level of commercial use.
Gasoline/Alcohol Blends - Gasoline
containing up to 10% ethanol (alcohol produced from agricultural products
such as corn), also known as "gasohol"
is approved for use.
CAUTION
Avoid using blends of unleaded
gasoline and methanol (wood
alcohol) whenever possible, and
never use "gasohol" containing more than 5% methanol.
Fuel system damage and performance problems may result.
Gasoline/Ether Blends - The most
common ether is methyl tertiary butyl
ether (MTBE). You may use gasoline
containing up to 15% MTBE.
NOTE
Other oxygenates approved for use
in unleaded gasoline include TAME

(up to 16.7 %) and ETBE (up to
17.2 %). Fuel containing these oxygenates can also be used in your
Kawasaki.
CAUTION
CAUTION
Never use gasoline with an octane rating lower than the minimum specified by Kawasaki.
Never use "gasohol" with more
than 10% ethanol, or more than
5% methanol.
Gasoline containing methanol must also be
blended with cosolvents and
corrosion inhibitors.
Certain ingredients of gasoline
may cause paint fading or damage. Be extra careful not to spill
gasoline or gasoline oxygenate
blends during refueling.
When not operating your
Kawasaki for 30 to 60 days, mix a
fuel stabilizer (such as STA-BIL)
with the gasoline in the fuel tank.
Fuel stabilizer additives inhibit
oxidation of the fuel which minimizes gummy deposits.
Never store this product with

"gasohol" in the fuel system.
Before storage it is recommended that you drain all fuel
from the fuel tank and carburetor. See the Storage section in
this manual.
Fuel Tap
The fuel tap is an automatic type
which shuts off the fuel supply when
the engine is stopped in the ON or RES
position.
the ON position. If the fuel runs out with

the tap in the ON position, turn the tap
lever to PRI, leave it for a few seconds,
and then turn it to RES. The last 3.0 L
(0.80 US gal) of fuel can be used by
turning the fuel tap lever to RES.
The PRI position bypasses the automatic control and is useful for priming
the engine after running out of gas, or
for completely draining the fuel tank.
NOTE
Since riding distance is limited when

A.
B.
C.
D.
Fuel Tap
ON position
PRI position
RES position
The fuel tap has three positions: ON,

RES (reserve), and PRI (prime). For
nomal operation, turn the tap lever to
on RES, refuel at the earliest opportunity.

Make certain that the fuel tap lever is
turned to ON (Not RES) after filling
up the fuel tank.
To start a cold engine after the motorcycle has been stored for a long time,
first turn the tap lever to PRI, leave it
for a moment, and return it to ON.
WARNING
Practice operating the fuel tap
with the motorcycle stopped. To
prevent an accident you should
be able to operate the fuel tap
while riding without taking your
eyes off the road.
Be careful not to touch the hot
engine while operating the fuel
tap.
Do not leave the fuel tap in the
PRI (prime) position while riding
or parking the motorcycle. The
engine may become flooded or
fuel may spill onto the ground
and create a fire hazard, if the
vehicle falls over.
Stand
The motorcycle is equipped with a
side stand.
A. Side Stand
NOTE
When using the side stand, turn the

handlebar to the left.
Whenever the side stand is used,

make it a practice to kick the stand fully
up before sitting on the motorcycle.
NOTE
The
motorcycle is equipped with a

side stand switch. This switch is designed so that the engine dose not
start if the transmission is in gear and
the side stand is left down.
Helmet Hook
Helmet can be secured to the motorcycle using the helmet hook located at
the front of the tool kit case.
The helmet hook can be unlocked by
inserting the ignition key into the lock,
and turning the key to the right.
A. Helmet Hook
WARNING
Do not ride the motorcycle with a
helmet attached to the hook. The
helmet could cause an accident
by distracting the operator or interfering with normal vehicle operation.
Tool Kit Case/Tool Kit

The tool kit is stored in the tool kit
case.
The kit contains tools that can be
helpful in making roadside repairs, adjustments, and some maintenance procedures explained in this manual.
A. Tool Kit Case

B. Screw
Side Cover
The left and right side covers are removed for battery removal or installation and air cleaner element cleaning.
Right and Left Side Cover Removal
To remove the right and left side
cover, remove a screw of the left
side cover (two screws of the right
side cover), and pull out the left and
right side cover.
A. Tool Kit
A. Left Side Cover

B. Screw
A. Right Side Cover

B. Screws
Seat
Seat Removal
To remove the seat, follow this step.
1. Remove the left and right side covers.
2. Remove the seat mounting bolts.
3. Pull the seat up and to the rear.
A. Seat
B. Mounting Bolt
44 BREAK-IN
BREAK-IN
The first 1 600 km (1 000 mi) that the motorcycle is ridden is designated as the
break-in period. If the motorcycle is not used carefully during this period, you may
very well end up with a "broken down" instead of a "broken in" motorcycle after a
few thousand kilometers.
The following rules should be observed during the break-in period.
The table shows maximum recommended engine speed during the break-in period.
1st
2nd
3rd
4th
5th
6th
0 800 km (0 500 mi)
20
(12)
30
(18)
40
(25)
50
(31)
60
(38)
70
(44)
800 1,600 km (500 1,000 mi)
30
(18)
40
(25)
50
(31)
60
(38)
70
(44)
85
(53)
Gear Position
Distance traveled
NOTE
When operating on public roadways, keep maximum speed under traffic law limits.
BREAK-IN 45
not start moving or race the engine immediately after starting it, even if the
Do
engine is already warm. Run the engine for two or three minutes at idle speed to
give the oil a chance to work up into all the engine parts.
Do not race the engine while the transmission is in neutral.
WARNING
New tires are slippery and may cause loss of control and injury.
A break-in period of 160 km (100 miles) is necessary to establish normal
tire traction. During break-in, avoid sudden and maximum braking and
acceleration, and hard cornering.
In addition to the above, at 1 000 km (600 mi) it is extremely important that the
owner have the initial maintenance service performed by a compartment mechanic
following the procedures in the Service Manual.
46 HOW TO RIDE THE MOTORCYCLE
HOW TO RIDE THE MOTORCYCLE

Starting the Engine
the fuel tap lever to "ON" posi Turn

tion.
first turn the tap lever to PRI, leave it

for a moment, and return it to ON.
that the engine stop switch
Check
is in the RUN position (RUN switch
pushed in).
A. Fuel Tap Lever

B. ON position
NOTE
To start a cold engine after the motorcycle has been stored for a long time,
A. Engine Stop Switch

B. RUN Switch
C. Starter Button
HOW TO RIDE THE MOTORCYCLE 47
the ignition key to "ON".

Turn
Make
neutral.certain the transmission is in
the engine is cold, pull up the choke

Ifknob
all the way.
A. Choke Knob
A. Neutral Indicator Light
B. Ignition Switch
C. ON position
NOTE
When the engine is already warm or
on hot days (35C, 95F or more),

close the throttle completely without
using the choke knob, and then start
the engine.
the throttle completely

Leaving
closed, push the starter button.
prevents the electric starter from operating when the clutch is engaged
and the transmission is not in neutral.
CAUTION
Do not operate the starter continuously for more than 5 seconds or the starter will overheat
and the battery power will drop
temporarily. Wait 15 seconds
between each operation of the
starter to let it cool and the battery power recover.
NOTE
If the engine is flooded, crank the en-
gine over with the throttle fully open

until the engine starts.
The motorcycle is equipped with a
starter lockout switch. This switch
A. Clutch Lever
B. Starter Lockout Switch
push the choke knob back

Gradually
a little at a time as necessary to keep
the engine running properly during

warm-up.
When the engine is warmed up
enough to idle without using the
choke, and push the choke knob all

the way back.
NOTE
If
you drive the motorcycle before

the engine is warmed up, return the
choke knob all the way after you have
driven the motorcycle for the length
of time shown in the table.
CAUTION
Do not let the engine idle longer
than five minutes, or engine
overheating and damage may
occur.
Ambient
temperature
Choke off after

running for
20C (68F) 35C

15 seconds
(95F)
Below 20C (68F)
1.5 minutes
Below 5C (40F)
2 minutes
Jump Starting
WARNING
If your motorcycle battery is "run

down", it should be removed and
charged. If this is not practical, a 12
volt booster battery and jumper cables
may be used to start the engine.
Battery acid generates hydrogen gas which is flammable and

explosive under certain conditions. It is present within a
battery at all times, even in a
discharged condition. Keep all
flames and sparks (cigarettes)
away from the battery. Wear eye
protection when working with a
battery. In the event of battery
acid contact with skin, eyes, or
clothing, wash the affected areas immediately with water for at
least five minutes. Seek medical
attention.
Connecting Jumper Cables
Remove the left side cover.
Make sure the ignition key is turned
"OFF".
a jumper cable from the

Connect
positive (+) terminal of the booster
battery to the positive (+) battery terminal at the starter relay.
shift pedal or other unpainted metal

surface. Do not use the negative ()
terminal of the battery.
WARNING
A. Battery-connected Starter Relay Terminal

B. From Booster Battery Positive (+) Terminal
C. Unpainted Metal Surface
D. From Booster Battery Negative ()
Terminal
another jumper cable from

Connect
the negative () terminal of the
booster battery to your motorcycle
Do not make this last connection at the carburetor or battery.

Take care that you do not touch
the positive and negative cables
together, and do not lean over
the battery when making this last
connection. Do not jump start a
frozen battery. It could explode.
Do not reverse polarity by connecting positive (+) to negative
(), or a battery explosion and
serious damage to the electrical
system may occur.
the standard engine starting
Follow
procedure.
CAUTION
Do not operate the starter continuously for more than 5 seconds or the starter will overheat
and the battery power will drop
temporarily. Wait 15 seconds
between each operation of the
starter to let it cool and the battery power recover.
Moving Off
that the side stand is up.

Check
Pull
in
the
lever.
Shift into 1stclutch
gear.
Open the throttle a little, and start to
let out the clutch lever very slowly.
the clutch starts to engage, open
As
the throttle a little more, giving the engine just enough fuel to keep it from
stalling.
the engine has started, discon After

nect the jumper cables. Disconnect
the negative () cable from the motorcycle first.

Reinstall the parts removed.
A. Shift Pedal
NOTE
The
motorcycle is equipped with a

side stand switch. This switch is designed so that the engine stops if the
clutch is engaged with the transmission in gear when the side stand is
left down.
Shifting Gears
the throttle while pulling in the

Close
clutch lever.
into the next higher or lower
Shift
gear. For smooth riding, shift up or
down when the motorcycle is operated the speeds shown in the table.
Open the throttle part way, while releasing the clutch lever.
WARNING
When shifting down to a lower
gear, do not shift at such a high
speed that the engine r/min
(rpm) jumps excessively. Not
only can this cause engine damage, but the rear wheel may skid
and cause an accident. Downshifting should be done the vehicle speeds shown in the table
in this section.

Vehicle speed when shifting
Shifting up
km/h (mph)
Shifting down
km/h (mph)
1st 2nd
15 ( 9)
6th 5th
30 (19)
2nd 3rd
25 (15)
5th 4th
25 (15)
3rd 4th
35 (21)
4th 3rd
20 (12)
4th 5th
45 (27)
3rd 2nd
15 ( 9)
5th 6th
55 (34)
2nd 1st
15 ( 9)
Braking
Close the throttle completely, leaving the clutch engaged (except when
shifting gears) so that the engine will
help slow down the motorcycle.
Shift down one gear at a time so that
you are in 1st gear when you come
to a complete stop.
When stopping, always apply both
brakes at the same time. Normally
the front brake should be applied a little more than the rear. Shift down or
fully disengage the clutch as necessary to keep the engine from stalling.
Never lock the brakes, or it will cause
the tires to skid. When turning a corner, it is better not to brake at all. Reduce your speed before you get into
the corner.
emergency braking, disregard

For
downshifting, and concentrate on
applying the brakes as hard as possible without skidding.
A. Front Brake Lever
Stopping the Engine
the throttle completely.

Close
Shift
the
into neutral.
Turn the transmission
ignition
key
to
Support the motorcycle"OFF".
a firm
level surface with the side onstand.
Lock the steering.
A. Rear Brake Pedal
Stopping the Motorcycle in an

Emergency
Your Kawasaki Motorcycle has been
designed and manufactured to provide you optimum safety and convenience. However, in order to fully benefit from Kawasakis safety engineering
and craftsmanship, it is essential that
you, the owner and operator, properly
maintain your motorcycle and become
thoroughly familiar with its operation.
Improper maintenance can create a
dangerous situation known as throttle failure. Two of the most common
causes of throttle failure are:
1. An improperly serviced or clogged
air cleaner may allow dirt and dust
to enter the carburetor and stack the
throttle open.
2. During removal of the air cleaner,

dirt is allowed to enter and jam the
carburetor.
In an emergency situation such as
throttle failure, your vehicle may be
stopped by applying the brakes and
disengaging the clutch.
Once this
stopping procedure is initiated, the engine stop switch may be used to stop
the engine. If the engine stop switch is
used, turn off the ignition switch after
stopping the motorcycle.
Parking
the transmission into neutral

Shift
and turn the ignition key to "OFF".
the motorcycle on a firm,
Support
level surface with the side stand.
CAUTION
Do not park on a soft or steeply
inclined surface, or the motorcycle may fall over.
parking inside a garage or other
Ifstructure,
be sure it is well ventilated
and the motorcycle is not close to
any source of flame or sparks; this
includes any appliance with a pilot
light.
WARNING
Gasoline is extremely flammable
and can be explosive under certain conditions.
the
Lock
theft.
steering to help prevent
NOTE
When stopping near traffic at night,

you can leave taillight on for greater
visibility by turning the ignition key to
the P (Park) position.
Do not leave the ignition switch at P
position too long, or the battery will
discharge.
SAFE OPERATION 59
SAFE OPERATION
Safe Riding Technique
The points given below are applicable for everyday motorcycle use and should
be carefully observed for safe and effective vehicle operation.
For safety, eye protection and a
helmet are strongly recommended.
Gloves and suitable footwear
should also be used for added protection in case of a mishap.
A motorcycle does not provide
the impact protection of an automobile, so defensive riding in addition to wearing protective apparel
is extremely important. Do not let
protective apparel give you a false
sense of security.
Before changing lanes, look over

your shoulder to make sure the way
is clear. Do not rely solely on the
rear view mirror; you may misjudge
a vehicles distance and speed, or
you may not see it at all.
When going up steep slopes, shift
to a lower gear so that there is plenty
of power to spare rather than overloading the engine.
When applying the brakes, use
both the front and rear brakes. Applying only one brake for sudden
60 SAFE OPERATION
braking may cause the motorcycle

to skid and lose control.
When going down long slopes,
control vehicle speed by closing
the throttle. Use the front and rear
brakes for auxiliary braking.
When riding in wet conditions or

on loose roadway surfaces, the ability to maneuver will be reduced. All
of your actions should be smooth
under these conditions. Sudden acceleration, braking or turning may
cause loss of control.
In wet conditions, rely more on the

throttle to control vehicle speed and
less on the front and rear brakes.
The throttle should also be used judiciously to avoid skidding the rear
wheel from too rapid acceleration or
deceleration.
On rough roads, exercise caution,

slow down, and grip the fuel tank
with the knees for better stability.
Riding at the proper rate of speed

and avoiding unnecessarily fast acceleration are important not only for
safety and low fuel consumption but
also for long vehicle life and quieter
operation.
Do not downshift at too high an

r/min (rpm) to avoid damage to the
engine from overrevving.
When quick acceleration is necessary as in passing, shift to a lower

gear to obtain the necessary power.
Avoiding unnecessary weaving is

important to the safety of both the
rider and other motorists.
SAFE OPERATION 61
Daily Safety Checks

Check the following items each day before you ride. The time required is minimal,
and habitual performance of these checks will help ensure you a safe, reliable ride.
If any irregularities are found during these checks, refer to the Maintenance and
Adjustment chapter or see your dealer for the action required to return the motorcycle to a safe operating condition.
WARNING
Failure to perform these checks every day before you ride may result in
serious damage or a severe accident.
Fuel ............................. Adequate supply in tank, no leaks.
Engine oil .................... Oil level between level lines.
Tires ............................ Air pressure (when cold):
Front
Up to 165 kg (364 lb)

Load
Rear
Up to 97.5 kg (215 lb)

150 kPa (1.50 kgf/cm, 21 psi)
Load
97.5 165 kg (215
364 lb) Load
150 kPa (1.50 kgf/cm, 21 psi)
175 kPa (1.75 kgf/cm, 25 psi)
62 SAFE OPERATION
Drive chain .................. Slack 35 55 mm (1.4 2.2 in.).

Lubricate if dry
Nuts, bolts, fasteners .. Check that steering and suspension components, axles,
and all controls are properly tightened or fastened.
Steering ...................... Action smooth but not loose from lock to lock. No binding
of control cables.
Brakes ........................ Brake pad wear: Lining thickness more than 1 mm (0.04
in.) left.
No brake fluid leakage.
Brake lever play 2 5 mm (0.08 0.20 in.)
Throttle ....................... Throttle grip play 2 3 mm (0.08 0.12 in.).
Clutch ......................... Clutch lever play 2 3 mm (0.08 0.12 in.).
Clutch lever operates smoothly.
Electrical equipment ... All lights and horn work.
Engine stop switch ...... Stops engine.
Side stand ................... Return to its fully up position by spring tension.
Return spring not weak or not damaged.
Refer to the "Daily Safety Checks" caution label attached to the back of the right
side cover.
SAFE OPERATION 63
Additional Considerations for Off Road Operation

Brakes: The importance of reliable brakes is obvious. Check to see that they
are correctly adjusted and functioning properly.
Steering: Looseness in the steering can cause loss of control. Check to see that
the handlebar turns freely but has no play.
Tires: Due to the extra stress to the tires on rough roads, be sure to examine
their overall condition, and inflate them to the proper pressure.
Drive Chain: When not adjusted properly, the severe stress on rough roads can
cause damage to the sprockets and cause the chain to be thrown. Examine the
chain slack and alignment, and lubricate if necessary.
Fuel: Have sufficient fuel for the high fuel consumption on rough roads.
Engine Oil: To avoid engine seizure and resulting loss of control, make certain
the oil level is at the upper level line.
Miscellaneous: Check to see that the electrical equipment is functioning properly, all nuts and bolts are tight, and all safety related parts are in good condition.
64 MAINTENANCE AND ADJUSTMENT

The maintenance and adjustments outlined in this chapter are easily carried out
and must be done in accordance with the Periodic Maintenance Chart to keep the
motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected.
If you are in doubt as to any adjustment or vehicle operation, please ask your
authorized Kawasaki dealer to check the motorcycle.
Please note that Kawasaki cannot assume any responsibility for damage resulting from incorrect maintenance or improper adjustment done by the owner.
MAINTENANCE AND ADJUSTMENT 65
EMISSION CONTROL INFORMATION

To protect the environment in which we all live, Kawasaki has incorporated
crankcase emission (1) and exhaust emission (2) control systems in compliance
with applicable regulations of the United States Environmental Protection Agency.
1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors into the atmosphere.
Instead, the vapors are routed through an oil separator to the intake side of the
engine. While the engine is operating, the vapors are drawn into the combustion
chamber, where they are burned along with the fuel and air supplied by the carburetor.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere
by the exhaust of this motorcycle. The fuel and ignition systems of this motorcycle
have been carefully designed and constructed to ensure an efficient engine with
low exhaust pollutant levels.
High Altitude Performance Adjustment Information
To improve the EMISSION CONTROL PERFORMANCE of vehicles operated
above 4 000 feet, Kawasaki recommends the following Environmental Protection
Agency (EPA) approved modification.
NOTE
When properly performed, these specified modifications only are not considered
to be emissions system tampering and vehicle performance is generally unchanged as a result.
Installation Instructions:
High altitude adjustment requires replacement of certain carburetor components.
Installation of these optional parts may be performed by an authorized Kawasaki
dealer, or the consumer, following repair recommendations specified in the appropriate Kawasaki Service Manual.
MAINTENANCE AND WARRANTY

Proper maintenance is necessary to ensure that your motorcycle will continue to
have low emission levels. This Owners Manual contains those maintenance recommendations for your motorcycle. Those items identified by the Periodic Maintenance Chart are necessary to ensure compliance with the applicable standards.
As the owner of this motorcycle, you have the responsibility to make sure that
the recommended maintenance is carried out according to the instructions in this
Owners Manual at your own expense.
The Kawasaki Limited Emission Control System Warranty requires that you return your motorcycle to an authorized Kawasaki dealer for remedy under warranty.
Please read the warranty carefully, and keep it valid by complying with the owners
obligations it contains.
You should keep a maintenance record for your motorcycle. To assist you in
keeping this record, we have provided space on pages 138 through 142 of this
manual where an authorized Kawasaki dealer, or someone equally competent, can
record the maintenance. You should also retain copies of maintenance work orders,
bills, etc., as verification of this maintenance.
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:

Federal law prohibits the following acts or the causing thereof: (1) the removal or
rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new
vehicle for the purpose of noise control prior to its sale or delivery to the ultimate
purchaser or while it is in use, or (2) the use of the vehicle after such device or
element of design has been removed or rendered inoperative by any person.
*
*
*
*
Among those acts presumed to constitute tampering are the acts listed below:
Replacement of the original exhaust system or muffler with a component not in
compliance with Federal regulations.
Removal of the muffler(s) or any internal portion of the muffler(s).
Removal of the air box or air box cover.
Modifications to the muffler(s) or air intake system by cutting, drilling, or other
means if such modifications result in increased noise levels.
Periodic Maintenance Chart

K: Should be serviced by an authorized Kawasaki dealer.
*: For higher odometer readings, repeat at the frequency interval established here.
#: Service more frequently when operating in severe conditions: dusty, wet, muddy,
high speed, or frequent starting/stopping.
1. Periodic Inspection (Engine Related Items)
Frequency Whichever
comes
first
Operation (Engine
Items)
Air cleaner element clean
Valve clearance - inspect
Every
*Odometer Reading See

km 1000 ( mile 1000) Page
1
6
12
18
24
30
36
(0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
88
87

Frequency Whichever
comes
first
Operation (Engine
Items)
Every

1
6
12
18
24
30
(0.6) (3.75) (7.5) (11.25) (15) (18.75)
36
(22.5)
Throttle control
system (play, smooth
return, no drag) inspect
year
92
Choke operation inspect
year
Idle speed - inspect

K
Fuel leak (fuel hose

and pipe) - inspect
year
Fuel hoses damage

- inspect
year
94
Frequency Whichever
comes
first
Operation (Engine
Items)
Fuel hoses
K installation condition
- inspect
Air suction system
damage - inspect
Every
year

1
6
12
18
24
30
(0.6) (3.75) (7.5) (11.25) (15) (18.75)
36
(22.5)

2. Periodic Inspection (Chassis Related Items)
Frequency Whichever
comes
first
Operation (Chassis
Items)
Every

1
6
12
18
24
30
(0.6) (3.75) (7.5) (11.25) (15) (18.75)
36
(22.5)
Clutch and drive train:

Clutch operation
(play, engagement,
disengagement) inspect
95
Drive chain
lubrication condition
- inspect #
every 600 km (400 mile)
102
Drive chain slack inspect #
every 1 000 km (600 mile)
98
Drive chain wear inspect #
100
Frequency Whichever
comes
first
Operation (Chassis
Items)
K
Every

1
6
12
18
24
30
(0.6) (3.75) (7.5) (11.25) (15) (18.75)
Drive chain guide

wear - inspect
36
(22.5)
112
Wheels/tires damage
- inspect
Tire tread wear,

abnormal wear inspect
113
Wheels and tires:

Tire air pressure inspect
Wheel bearings
damage - inspect
Spoke tightness and

rim runout - inspect
year
year
113

Frequency Whichever
comes
first
Operation (Chassis
Items)
Every

1
6
12
18
24
30
(0.6) (3.75) (7.5) (11.25) (15) (18.75)
36
(22.5)
Brake system:
Brake fluid leak inspect
year
Brake hoses damage

- inspect
year
Brake pad wear inspect #

Brake hose
installation condition
- inspect
Brake fluid level inspect
107
105
year
6
months
106
Frequency Whichever
comes
first
Operation (Chassis
Items)
Every
Brake operation
(effectiveness, play,
drag) - inspect
year
Brake light switch

operation - inspect

1
6
12
18
24
30
(0.6) (3.75) (7.5) (11.25) (15) (18.75)
36
(22.5)
103
108
Suspensions:
Rear shock absorber
operation (damping
and smooth stroke) inspect
Front forks/rear
shock absorber oil
leak - inspect
K
Uni-trak rocker arm

bearings - lubricate
year
110

Frequency Whichever
comes
first
Operation (Chassis
Items)
K
Uni-trak rocker arm

operation - inspect
Uni-trak tie rods

operation - inspect
Uni-trak tie rods

Swing arm pivot lubricate
Every

1
6
12
18
24
30
(0.6) (3.75) (7.5) (11.25) (15) (18.75)
36
(22.5)
Steering system:
K
Steering play inspect
year
Frequency Whichever
comes
first
Operation (Chassis
Items)
Every
Steering stem
2
years

1
6
12
18
24
30
(0.6) (3.75) (7.5) (11.25) (15) (18.75)
36
(22.5)
Electrical system:
Lights and switches
operation - inspect
year
Headlight aiming inspect
year
Side stand switch

operation - inspect
year
Engine stop switch

operation - inspect
year
Chassis:
117

Frequency Whichever
comes
first
Operation (Chassis
Items)
Chassis parts lubricate
Bolts and nuts
tightness - inspect
Every

1
6
12
18
24
30
(0.6) (3.75) (7.5) (11.25) (15) (18.75)
year
36
(22.5)
121
127
3. Periodic Replacement
Frequency Whichever
comes
first
Change/Replacement Item
Air cleaner element # - replace
Every
1
12
24
36
48
(0.6) (7.5) (15) (22.5) (30)
2 years
Engine oil # - change
year
Oil filter - replace
year
K Fuel hoses - replace
4 years
K Brake hoses - replace
4 years
Brake fluid (front and rear) change
2 years
Rubber parts of master cylinder

and caliper - replace
4 years
Spark plug - replace

88
81
81
108
85
Engine Oil
In order for the engine, transmission,
and clutch to function properly, maintain the engine oil at the proper level,
and change the oil and oil filter in accordance with the Periodic Maintenance
Chart. Not only do dirt and metal particles collect in the oil, but the oil itself
loses its lubricative quality if used too
long.
WARNING
Motorcycle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure, accident, and injury.
Oil Level Inspection
Situate the motorcycle so that it is
perpendicular to the ground.
oil has just been changed, start

Ifthetheengine
and run it for several minutes at idle speed. This fills the oil
filter with oil. Stop the engine, then
wait several minutes until the oil settles.
CAUTION
Racing the engine before the oil
reaches every part can cause engine seizure.
the motorcycle has just been used,
Ifwait
several minutes for all the oil to
drain down.
the engine oil level through

Check
the oil level gauge. With the motorcycle held level, the oil level should
come up between the upper and
lower level lines next to the gauge.
Oil and/or Oil Filter Change

Warm up the engine thoroughly, and
then stop it.
Set the motorcycle up on its side
stand.
Remove the bolt of the engine guard,
and take off the engine guard.
A.
B.
C.
D.
Oil Filler Cap

Oil Level Gauge
Upper Level Line
Lower Level Line
the oil level is too high, remove the

Ifexcess
oil through the oil filler open-
ing using a syringe or same other

suitable device.
If the oil level is too low, add the oil
to reach the correct level. Use the
same type and brand of oil that is
already in the engine.
A. Engine Guard
B. Bolt
an oil pan beneath the engine.

Place
Remove the engine oil drain plug.
the oil filter is to be changed, re Ifmove

the oil filter cover bolts and
take off the cover with O-ring.
A. Drain Plug
the oil completely drain with

Let
the motorcycle perpendicular to the
ground.
A. Bolts
B. Oil Filter Cover
WARNING
Motor oil is a toxic substance.
Dispose of used oil properly.
Contact your local authorities
for approved disposal methods
or possible recycling.
the element with a new one.

Replace
Put
the
spring
and element into the
right engine cover.
with its gasket. Proper torque for it is

shown in the table.
NOTE
Replace the any gasket with a new

one.
the engine up to the upper level

Fill
line with a good quality motor oil
A. Element
B. Grommet
C. Spring
a little engine oil to the grom Apply

met and O-ring, and install the oil filter cover and tighten its bolts.
the oil has completely drained
After
out, install the engine oil drain plug
specified in the table.

Start the engine.
Check the oil level and for oil leakage.
Install the engine guard.
Tightening Torque
Engine Oil Drain Plug:
15 Nm (1.5 kgfm, 11 ftlb)
NOTE
If a torque wrench is not available,

this item should be serviced by a
Kawasaki dealer.

Recommended Engine Oil
Type:
API SE, SF or SG
API SH, SJ, SL or SM with
JASO MA, MA1 or MA2
Viscosity: SAE 10W-40
NOTE
Do not add any chemical additive to

the oil. Oils fufilling the above requirements are fully formulated and
provide adequate lubrication for both
the engine and the clutch.
Engine Oil Capacity

Capacity: 1.3 L (1.4 US qt)
[when filter is not removed]
1.4 L (1.5 US qt)
[when filter is removed]
1.5 L (1.6 US qt)
[when engine is completely
dry]
Although 10W-40 engine oil is the

recommended oil for most conditions, the oil viscosity may need to be
changed to accumulate atmospheric
conditions in your riding area.
Spark Plugs
The standard spark plug is shown in
the table. The spark plug should be
taken out in accordance with the Periodic Maintenance Chart for cleaning,
inspection, and resetting of the plug
gap.
Maintenance
If the plug is oily or has carbon built
up on it, have it cleaned, preferably in
a sand-blasting device, and then clean
off any abrasive particles. The plug
may also be cleaned using a high-flash
point solvent and a wire brush or other
suitable tool. Measure the gap with a
wire-type thickness gauge, and adjust
the gap if incorrect by bending the outer
electrode. If the spark plug electrodes
are corroded or damaged, or if the insulator is cracked, replace the plug. Use
the standard plug.
Spark Plug
Standard Plug
NGK CR8E,
ND U24ESR-N
Plug Gap
0.7 0.8 mm
(0.028 0.031 in.)
Tightening
Torque
13 Nm
(1.3 kgfm, 115 inlb)
A. Plug Gap
NOTE
If a torque wrench is not available,

this item should be serviced by a
Kawasaki dealer.
CAUTION
For cold weather and/or low
speed riding, a hotter spark plug
shown in the table may be used
for quicker warm-ups and more
efficient engine operation. However, for normal temperatures
and/or high speed use, the standard spark plug must be used to
prevent engine damage.
Hotter Spark Plug
NGK CR7E
NOTE
When
installing the spark plug cap

onto the spark plug, fit the plug cap
securely onto the spark plug, and pull
the cap lightly to make sure that it is
properly installed.
Valve Clearance
Air Cleaner
Valve and valve seat wear decreases

valve clearance, upsetting valve timing.
A clogged air cleaner restricts the engines air intake, increasing fuel consumption, reducing engine power, and
causing spark plug fouling.
The air cleaner element must be
cleaned in accordance with the Periodic Maintenance Chart. In dusty areas, the element should be cleaned
more frequently than the recommended interval. After riding through
rain or on muddy roads, the element
should be cleaned immediately. The
element should be replaced if it is damaged.
CAUTION
If valve clearance is left unadjusted, wear will eventually
cause the valves to remain
partly open, which lowers performance, burns the valves and
valve seats, and may cause serious engine damage.
Valve clearance for each valve
should be checked and adjusted in
accordance with the Periodic Maintenance Chart.
Inspection and adjustment should be
done only by a competent following the
Service Manual.
Element Removal
Remove the right side cover.
Unscrew the air cleaner element cap
screws and bolt, then remove the air
cleaner element cap.
out the air cleaner element from

Pull
the air cleaner housing.
A. Element
A. Air Cleaner Element Cap

B. Screws
C. Bolt
Remove the element from the frame.
WARNING
If dirt or dust is allowed to pass
through into the carburetor, the
throttle may become stuck, possibly causing accident.
CAUTION
A. Element
B. Frame
a clean, lint-free towel into the

Push
air cleaner housing to keep dirt or
other foreign material from entering.

Inspect the element material for damage. If any part of the element is
damaged, the element must be replaced.
If dirt gets through into the engine, excessive engine wear and
possibly engine damage will occur.
NOTE
Element installation is performed in

the reverse order of removal.
Element Cleaning
the element in a bath of a high

Clean
-flash point solvent.
the element with compressed air

Dry
or by squeezing it.
cleaning, saturate the element
After
with SE, SF or SG class SAE 10W40
motor oil, squeeze out the excess
oil, then wrap it in a clean rag and
squeeze it as dry as possible. Be
careful not to tear the element.
Oil Draining
Inspect the transparent drain hoses
located at the lower end of the air
cleaner housing to see if any oil has
run down from the air cleaner housing.
WARNING
Clean the element in a well ventilated area, and take care that
there are no sparks or flame anywhere near the working area;
this includes any appliance with
a pilot light. Do not use gasoline or a low flash-point solvent
to clean the element. A fire or
explosion could result.
A. Drain Hoses
B. Plugs
there are any oil in the drain hoses,

Ifremove
the plugs from the lower end
of the drain hoses and drain the oil.
WARNING
Be sure to install each plug in
the drain hose after draining. Oil
on tires will make them slippery
and can cause an accident and
injury.
Throttle Grip
The throttle grip controls the throttle
valves. If the throttle grip has excessive play due to either cable stretch or
maladjustment, it will cause a delay in
throttle response, especially at low engine speed. Also, the throttle valves
may not open fully at full throttle. On
the other hand, if the throttle grip has
no play, the throttle will be hard to control, and the idle speed will be erratic.
Check the throttle grip play in accordance with the Periodic Maintenance
Chart, and adjust the play if necessary.
Inspection
Check that there is 2 3 mm (0.08
0.12 in.) throttle grip play when
lightly turning the throttle grip back
and forth.
If there is improper play, adjust it.
A. Throttle Grip
B. 2 3 mm (0.08 0.12 in.)
Adjustment
Loosen the locknut at the upper end
of the throttle cable, and turn the
adjuster until the proper amount of
throttle grip play is obtained.
A. Locknut
B. Adjuster
C. Throttle Cable (Accelerator Cable)
the locknut.
Tighten
If
the
throttle
can not be ad justed by usingcable
the cable adjuster at
the upper end of the throttle cable,
use the upper and lower nuts at the

lower ends of the throttle cables.
Loosen the locknut at the upper end
of the throttle cable and turn in the
adjuster fully.
Tighten the locknut.
Turn the upper and lower nuts at the
lower end of the decelerator cable
until there is no play when the throttle
grip is completely closed. Tighten the
nuts.
Turn the upper and lower nuts at the
lower end of the accelerator cable
until 2 3 mm (0.08 0.12 in.) of
throttle grip play is obtained. Tighten
the nuts.
A.
B.
C.
D.
Upper Nuts
Lower Nuts
Accelerator Cable
Decelerator Cable
there is excess play, use the ad Ifjuster

at the upper end of the throttle
cable.
WARNING
Operation with improperly adjusted, incorrectly routed, or
damaged cables could result in
an unsafe riding condition.
Carburetors
The following procedure covers the
idle speed adjustment, which should be
performed in accordance with the Periodic Maintenance Chart or whenever
the idle speed is disturbed.
Adjustment
Start the engine, and warm it up thoroughly.
Adjust the idle speed to 1 250 1
350 r/min (rpm) by turning the idle
adjusting screw.
and close the throttle a few

Open
times to make sure that the idle
speed does not change. Readjust if

necessary.
With the engine idling, turn the handlebar to each side. If handlebar
movement changes the idle speed,
the throttle cables may be improperly
adjusted or incorrectly routed, or they
may be damaged. Be sure to correct

any of these conditions before riding.
Clutch
Due to friction plate wear and clutch
cable stretch over a long period of use,
the clutch must be adjusted in accordance with the Periodic Maintenance
Chart.
WARNING
To avoid a serious burn, never
touch a hot engine or an exhaust
pipe during clutch adjustment.
A. Idle Adjusting Screw
WARNING
Operation with damaged cables
could result in an unsafe riding
condition.
Inspection
Check that the clutch lever has 2 3
mm (0.08 0.12 in.) of play as shown
in the figure.
the adjuster at the upper end of

Turn
the cable so that the clutch lever will
have 2 3 mm (0.08 0.12 in.) of
play.
WARNING
A.
B.
C.
D.
Adjuster
Locknut
Clutch Lever
2 3 mm (0.08 0.12 in.)
If the play is incorrect, adjust the lever

play as follows.
Adjustment
Slide the dust cover at the clutch
lever out of place.
Loosen the locknut at the clutch
lever.
Be sure the upper end of the

clutch outer cable is fully seated
in its fitting, or it could slip into
place later, creating enough cable play to prevent clutch disengagement, resulting in a hazardous riding condition.
Tighten the locknut.

be done, use the adjusting
Ifnutit cannot
at the middle of the clutch cable.
the locknut at the clutch
Loosen
lever.
the adjuster in all the way, then
Turn
tighten the locknut.
the locknut at the middle of

Loosen
the clutch cable, and turn the adjusting nut so that the clutch lever has 2
3 mm (0.08 0.12 in.) of play.
NOTE
After
the adjustment is made, start

the engine and check that the clutch
does not slip and that it releases
properly.
WARNING
Do not run the engine in a
closed area.
Exhaust gases
contain carbon monoxide; a colorless, odorless, poisonous gas.
Breathing exhaust gas leads to
carbon monoxide poisoning, asphyxiation, and death.
A. Adjusting Nut
B. Locknut
the locknut.
Tighten
Slide the dust cover back into place.
Drive Chain
The drive chain must be checked,
adjusted, and lubricated in accordance
with the Periodic Maintenance Chart
for safety and to prevent excessive
wear. If the chain becomes badly worn
or maladjusted - either too loose or
too tight - the chain could jump off the
sprockets or break.
the rear wheel to find the po Rotate

sition where the chain is tightest and
measure the maximum chain slack
by pulling up and pushing down the
chain midway between the engine
sprocket and rear wheel sprocket.
WARNING
A chain that breaks or jumps off
the sprockets could snag on the
engine sprocket or lock the rear
wheel, severely damaging the
motorcycle and causing it to go
out of control.
Chain Slack Inspection
Set the motorcycle up on its side
stand.
A. 35 55 mm (1.4 2.2 in.)
the drive chain is too tight or too

Ifloose,
adjust it so that the chain slack
will be within the standard value.
Drive Chain Slack

Standard
35 55 mm (1.4 2.2 in.)
Chain Slack Adjustment

Remove the cotter pin, and loosen
the axle nut.
Rotate the chain adjuster at each end
of the swingarm to obtain the standard chain slack.
A. Axle Nut
B. Chain Adjuster
C. Projection
D. Numbers
E. Cotter Pin
NOTE
Wheel
alignment can also be

checked using the straightedge or
string method.
WARNING
Misalignment of the wheel will
result in abnormal wear, and may
result in an unsafe riding condition.
the rear brake (see the Brakes

Check
section).
WARNING
If the axle nut is not securely
tightened or the cotter pin is not
installed, an unsafe riding condition may result.
the axle nut to the specified

Tighten
torque.
Tightening Torque
Axle Nut:
88 Nm (9.0 kgfm, 65 ftlb)
Rotate the wheel, measure the chain

slack again at the tightest position,
and readjust if necessary.
Insert a new cotter pin through the
axle nut, and spread its ends.
Wear Inspection
Stretch the chain taut either by using
the chain adjusters, or by hanging a
10 kg (20 lb) weight on the chain.
the length of 20 links on

Measure
the straight part of the chain from pin
center of the 1st pin to pin center of

the 21st pin. Since the chain may
wear unevenly, take measurements
at several places.
If the length exceeds the service limit,
the chain should be replaced.
Drive Chain 20-Link Length

Service Limit: 323 mm (12.7 in.)
WARNING
For safety, use only the standard
chain. It is an endless type and
should not be cut for installation; have it installed by an authorized Kawasaki dealer.
the rear wheel to inspect the
Rotate
drive chain for damaged rollers, and
A. Measure
B. Weight
loose pins and links.

Also inspect the sprockets for unevenly or excessively worn teeth,
and damaged teeth.
NOTE
Sprocket wear is exaggerated for il-
lustration. See Service Manual for

wear limits.
there is any irregularity, have the

Ifdrive
chain and/or the sprockets replaced by an authorized Kawasaki
dealer.
Lubrication
Lubrication is also necessary after
riding through rain or on wet roads, or
any time that the chain appears dry. A
heavy oil such as SAE 90 is preferred
to a lighter oil because it will stay on the
chain longer and provide better lubrication.
oil to the sides of the rollers so

Apply
that it will penetrate to the rollers and
bushings. Apply oil to the O-rings so
that the O-rings will be coated with
oil. Wipe off any excess oil.
the chain is especially dirty, clean it

Ifusing
diesel oil or kerosine and then
apply oil as described above.
Brakes
Disc and disc pad wear is automatically compensated for and has no effect on the brake lever or pedal action.
So there are no parts that require adjustment on the brakes except brake
lever play.
Front Brake Lever Play
The brake lever has 2 5 mm (0.08
0.20 in.) of play when the brake is
lightly applied.
To adjust the brake lever play, loosen
the locknut and turn the adjuster to either side. After adjustment, tighten the
locknut securely and check the braking
effectiveness.
A. Brake Lever
B. 2 5 mm (0.08 0.20 in.)
WARNING
If the brake lever or pedal feels
mushy when it is applied, there
might be air in the brake lines
or the brake may be defective.
Since it is dangerous to operate
the motorcycle under such conditions, have the brake checked
immediately.
A. Brake Lever
B. Adjuster
C. Locknut
Brake Wear Inspection

In accordance with the Periodic Maintenance chart, inspect the brakes for
wear. For each front and rear disc
brake caliper, if the thickness of either
pad is less than 1 mm (0.04 in.), replace
both pads in the caliper as a set. Pad
replacement should be done by an authorized Kawasaki dealer.
Disc Brake Fluid In accordance with the Periodic Maintenance Chart, inspect the brake fluid
level in both the front and rear brake
fluid reservoir and change the brake
fluid. The brake fluid should also be
changed if it becomes contaminated
with dirt or water.
Fluid Requirement
Use heavy-duty brake fluid only from
a container marked DOT3 or DOT4.
NOTE
Brake fluid of DOT4 is installed in the

brake system when shipped.
A. Lining Thickness
B. 1 mm (0.04 in.)
CAUTION
Do not spill brake fluid onto any
painted surface.
Do not use fluid from a container
that has been left open or that
has been unsealed for a long
time.
Check for fluid leakage around
the fittings.
Check brake hose for damage.
Fluid Level Inspection

The brake fluid level in the front brake
fluid reservoir must be kept above
the line (lower level line) next to the
gauge and that in the rear brake fluid
reservoir (located under the right side
cover) must be kept between the upper and lower level lines (reservoirs
held horizontal).
A. Front Brake Fluid Reservoir

B. Lower Level Line
the fluid level in ether reservoir is

Iflower
than the lower level line, check
for fluid leaks in the brake lines, and
fill the reservoir to the upper level
line. Inside the front brake fluid reservoir is a stepped line showing the upper level line.
A.
B.
C.
D.
Rear Brake Fluid Reservoir

Upper Level Line
Lower Level Line
Cap
A. Front Brake Fluid Reservoir

B. Upper Level Line
WARNING
Do not mix two brands of brake
fluid. Change the brake fluid in
the brake line completely if the
brake fluid must be refilled but
the type and brand of the brake
fluid that is already in the reservoir are unidentified.
Fluid Change
Have the brake fluid changed by an
authorized Kawasaki dealer.
Brake Light Switches

When either the front or rear brake is
applied, the brake light goes on. The
front brake light switch requires no adjustment, but the rear brake light switch
should be adjusted in accordance with
the Periodic Maintenance Chart.
Inspection
Turn the ignition key to "ON".
The brake light should go on when
the front brake is applied.
If it does not, ask your authorized
Kawasaki dealer to inspect the front
brake light switch.
the operation of the rear brake

Check
light switch by depressing the brake
pedal. The brake light should go on
after about 10 mm (0.4 in.) of pedal
travel.
Adjustment
To adjust the rear brake light switch,
move the switch up or down by turning the adjusting nut.
CAUTION
To avoid damaging the electrical
connections inside the switch,
be sure that the switch body
does not turn during adjustment.
A. Brake Pedal
B. 10 mm (0.4 in.)
not, adjust the rear brake

Iflightit does
switch.
Rear Shock Absorber

The rear shock absorber can be adjusted by changing the spring preload
and rebound damping force for various riding and loading conditions. Before making any adjustments, however,
read the following procedures.
A.
B.
C.
D.
Rear Brake Light Switch

Adjusting Nut
Lights sooner
Lights later
Spring Preload Adjustment

The spring adjusting nut on the rear
shock absorber can be adjusted.
If the spring action feels too soft or too
stiff, have it adjusted by an authorized
Kawasaki dealer.
Rebound Damping Force Adjustment
The rebound damping force adjuster
at the lower end of the rear shock absorber has 20 adjustment clicks.
First turn the rebound damping force
adjuster all the way clockwise with
a screwdriver to make the damping
force greatest.
the adjuster counterclockwise

Turn
to decrease damping force.
Rebound Damping
Force Adjuster
7 turns out*
* out from the fully seated position
A. Rebound Damping Adjuster

B. Mark
The standard setting position of the

rebound damping force adjuster for an
average-build rider of 68kg (150 lb) with
no passenger and no accessories are
as follows.
Tire pressure is affected by changes
Wheels
Tires Payload and Tire Pressure
Failure to maintain proper inflation
pressures or observe payload limits for
your tires may adversely affect handling and performance of your motorcycle and can result in loss of control. The
maximum recommended load in addition to vehicle weight is 165 kg (364 lb),
including rider, passenger, baggage,
and accessories.
Check the tire pressure often, using
an accurate gauge.
in ambient temperature and altitude,

and so the tire pressure should be
checked and adjusted when your riding involves wide variations in temperature or altitude.
NOTE
Measure the tire pressure when the

tires are cold (that is, when the motorcycle has not been ridden more
than a mile during the past 3 hours).
A. Tire Pressure Gauge
Tire Air Pressure (when cold)

Up to 165 kg
150 kPa (1.50
Front
kgf/cm, 21 psi)
(364 lb) Load
Rear
Up to 97.5 kg
(215 lb) Load
150 kPa (1.50

kgf/cm, 21 psi)
97.5 165 kg
(215 364 lb)
Load
175 kPa (1.75

kgf/cm, 25 psi)
Tire Wear, Damage

As the tire tread wears down, the tire
becomes more susceptible to puncture
and failure. An accepted estimate is
that 90% of all tire failures occur during
the last 10% of tread life (90 % worn).
So it is false economy and unsafe to
use the tires until they are bald.
accordance with
InMaintenance
Chart,
the Periodic
measure the
depth of the tread with a depth
gauge, and replace any tire that
has worn down to the minimum allowable tread depth.
A. Tire Depth Gauge
Minimum Tread Depth

Front
2 mm (0.08 in.)
Rear
2 mm (0.08 in.)
inspect the tire for cracks

Visually
and cuts, replacing the tire in case of
bad damage. Swelling or high spots

indicate internal damage, requiring
tire replacement.
Remove any imbedded stones or
other foreign particles from the tread.
NOTE
Have
the wheel balance inspected

whenever a new tire is installed.
WARNING
To ensure safe handling and
stability, use only the recommended standard tires for replacement, inflated to the standard pressure.
Standard Tire
Front Size:
2.75-21 45P
BRIDGESTONE TRAIL
WING-301
Rear Size:
4.10-18 59P
BRIDGESTONE TRAIL
WING-302
WARNING
Use the same manufactures
tires on both front and rear
wheels.
WARNING
New tires are slippery and may
cause loss of control and injury.
A break-in period of 160 km (100
miles) is necessary to establish normal tire traction. During
break-in, avoid sudden and maximum braking and acceleration,
and hard cornering.
Battery
The battery installed in this motorcycle is a sealed type, so it is not necessary to check the battery electrolyte
level or add distilled water.
The sealing strip should not be pulled
off once the specified electrolyte has
been installed in the battery for initial
service.
Since the electrical system of this
motorcycle is desighned to use only a
sealed battery, do not replace it with a
conventional battery.
CAUTION
Never remove the sealing strip,
or the battery can be damaged.
Do not install a conventional
battery in this motorcycle, or the
electrical system cannot work
properly.
NOTE
If
you charge the sealed battery,

never fail to observe the instructions
shown in the label on the battery.
Battery Removal
Remove the left side cover.
Disconnect the leads from the battery, first from the () terminal and
then the (+) terminal.
WARNING
Battery posts, terminals and related accessories contain lead
and lead compounds.
Wash
hands after handling.
A.
B.
C.
D.
() Terminal
(+) Terminal
Battery
Band
the battery band, and take

Remove
the battery out of the battery case.
the battery using a solution of

Clean
baking soda and water. Be sure that
the lead connections are clean.
Battery Installation
Put the battery in the battery case.
Connect the capped lead to the (+)
terminal, and then connect the black
lead to the () terminal.
Put a light coat of grease on the terminals to prevent corrosion.
Cover the (+) terminal with its protective cap.
Reinstall the parts removed.
Headlight Beam
Horizontal Adjustment
The headlight beam is adjustable
horizontally. If not properly adjusted
horizontally, the beam will point to one
side rather than straight ahead.
Turn the horizontal adjusting screw
on the headlight rim in or out until the
beam points straight ahead.
A. Vertical Adjusting Screw

B. Horizontal Adjusting Screw
Vertical Adjustment
The headlight beam is adjustable vertically. If adjusted too low, neither low
nor high beam will illuminate the road
far enough ahead. If adjusted too high,
the high beam will fail to illuminate the
road close ahead, and the low beam
will blind oncoming driver.
Turn the vertical adjusting screw on
the headlight rim in or out to adjust
the headlight vertically.
NOTE
On
high beam, the brightest point

should be slightly below horizontal.
The proper angle is 0.4 degrees below horizontal. This is a 50 mm (2
in.) drop at 7.6 m (25 ft) measured
from the center of the headlight, with
the motorcycle on its wheels and the
rider seated.
CAUTION
When handling the quartz
-halogen bulbs, never touch the
glass portion with bare hands.
Always use a clean cloth. Oil
contamination from hands or
dirty rags can reduce bulb life or
cause the bulb to explode.
Fuses
The main fuse is mounted on the
starter relay located to the left side of
the battery. The fuse case is located to
the left side of the starter relay. If a fuse
fails during operation, inspect the electrical system to determine the cause,
and then replace it with a new fuse of
proper amperage.
A. Main Fuse (20 A)

B. Fuse Case
C. Spare Fuse
WARNING
Do not use any substitute for the
standard fuse.
Replace the blown fuse with a
new one of the correct capacity,
as specified on the fuse case.
A. Normal
B. Failed
A. Normal
B. Failed
General Lubrication
Lubricate the points shown below,
with either motor oil or regular grease,
in accordance with the Periodic Maintenance Chart or whenever the vehicle
has been operated under wet or rainy
conditions.
Before lubricating each part, clean off
any rusty spots with rust remover and
wipe off any grease, oil, dirt, or grime.
NOTE
few drops of oil are effective to

keep bolts and nuts from rusting and
sticking. This makes removal easier.
Badly rusted nuts, bolts, etc., should
be replaced with new ones.
Apply motor oil to the following

pivots Side Stand
Clutch Lever
Front Brake Lever
Rear Brake Pedal
Lubricate the following cables with a
pressure cable lubber Clutch Inner Cable
Throttle Inner Cables
Apply grease to the following

points Clutch Inner Cable Upper End
Throttle Inner Cable Upper Ends
* Grease the lower part of the inner
cable sparingly.
NOTE
After
them.
connecting the cables, adjust
Cleaning Your Motorcycle

General Precautions
Frequent and proper care of your
Kawasaki motorcycle will enhance
its appearance, optimize overall performance, and extend its useful life.
Covering your motorcycle with a high
quality, breathable motorcycle cover
will help protect its finish from harmful
UV rays, pollutants, and reduce the
amount of dust reaching its surfaces.
Be sure the engine and exhaust are
cool before washing.
Avoid applying degreaser to seals,
brake pads, and tires.
Always use non-abrasive wax and
cleaner/polisher.
Avoid all harsh chemicals, solvents,
detergents, and household cleaning
products such as ammonia-based
window cleaners.
brake fluid, and coolant

Gasoline,
will damage the finish of painted and
a mild neutral detergent (de Mix

signed for motorcycles or automo-
plastic surfaces: wash them off immediately.

Avoid wire brushes, steel wool, and
all other abrasive pads or brushes.
Use care when washing the headlight cover, and other plastic parts as
they can easily be scratched.
Avoid using pressure washers; water can penetrate seals and electrical
components and damage your motorcycle.
Avoid spraying water in delicate areas such as in air intakes, carburetors, brake components, electrical
components, muffler outlets, and fuel
tank openings.
biles) and water in bucket. Use

a soft cloth or sponge to wash your
motorcycle. If needed, use a mild degreaser to remove any oil or grease
build up.
After washing, rinse your motorcycle thoroughly with clean water to remove any residue (residue from the
detergent can damage parts of your
motorcycle).
Use a soft cloth to dry your motorcycle. As you dry, inspect your motorcycle for chips and scratches. Do not
let the water air dry as this can damage the painted surfaces.
Start the engine and let it idle for several minutes. The heat from the engine will help dry moist areas.
Carefully ride your motorcycle at a
slow speed and apply the brakes
several times. This helps dry the
Washing Your Motorcycle

Rinse your bike with cold water from
a garden hose to remove any loose
dirt.
brakes and restores them to normal

operating performance.
Lubricate the drive chain to prevent
rusting.
NOTE
After riding in an area where the

roads are salted or near the ocean,
immediately wash your motorcycle
with cold water. Do not use warm
water as it accelerates the chemical
reaction of the salt. After drying,
apply a corrosion protection spray
on all metal and chrome surfaces to
prevent corrosion.
Painted Surfaces
After washing your motorcycle, coat
painted surfaces, both metal and plastic, with a commercially available motorcycle/automotive wax. Wax should
be applied once every three months or
as conditions require. Avoid surfaces
with "satin" or "flat" finishes. Always
use non-abrasive products and apply
them according to the instructions on
the container.
Plastic Parts
After washing use a soft cloth to gently dry plastic parts. When dry, treat the
headlight lens, and other non-painted
plastic parts with an approved plastic
cleaner/polisher product.
CAUTION
Plastic parts may deteriorate
and brake if they come in contact with chemical substances
or household cleaning products
such as gasoline, brake fluid,
window cleaners, thread-locking
agents, or other harsh chemicals. If a plastic part comes in
contact with any harsh chemical
substance, wash it off immediately with water and a mild neutral detergent, and then inspect
for damage. Avoid using abrasive pads or brushes to clean
plastic parts, as they will damage the parts finish.
Chrome and Aluminum
Chrome and uncoated aluminum
parts can be treated with a chrome/aluminum polish.
Coated aluminum
should be washed with a mild neutral detergent and finished with a spray
polish. Aluminum wheels, both painted
and unpainted can be cleaned with
special non-acid based wheel spray
cleaners.
Leather, Vinyl, and Rubber
If your motorcycle has leather accessories, special care must be taken.
Use a leather cleaner/treatment to
clean and care for leather accessories.
Washing leather parts with detergent
and water will damage them, shortening their life.
Vinyl parts should be washed with the
rest of the motorcycle, then treated with
a vinyl treatment.
The sidewalls of tires and other rubber components should be treated with
a rubber protectant to help prolong their
useful life.
WARNING
Special care must be taken not to
get any rubber protectant on the
tires tread surface when treating tires. This may decrease the
tires ability to maintain contact
with the road surface causing
the rider to lose control.
Bolt and Nut Tightening

In accordance with the Periodic Maintenance Chart, it is very important to check
the tightness of the bolts and nuts listed here. Also, check to see that each cotter
pin is in place and in good condition. Please ask your authorized Kawasaki dealer
for torque values.
1. Front Fender Mounting
Bolts
2. Front Fork Clamp Bolts
3. Clutch Lever Holder Bolts
4. Handlebar Clamp Bolts
5. Steering Stem Head Bolt
6. Cylinder Head Bolts
7. Rear Shock Absorber
Mounting Bolts and Nuts
8. Caliper Mounting Bolts
9. Spokes
10. Engine Mounting Bolts
and Nuts
11. Shift Pedal Bolt
12. Swingarm Pivot Shaft Bolt

13.
14.
15.
16.
17.
Muffler Mounting Bolts

Brake Lever Holder Bolt
Rear Axle Nut
Exhaust Pipe Holder Nuts
Front Axle Nut
STORAGE 129
STORAGE
Preparation for Storage:
Clean the entire vehicle thoroughly.
Run the engine for about five minutes to warm the oil, shut it off and drain the
engine oil.
WARNING
Motor oil is a toxic substance. Dispose of used oil properly. Contact your
local authorities for approved disposal methods or possible recycling.
in fresh engine oil.
Put
Empty
the fuel from the fuel tank, and empty the carburetors by unscrewing the
drain screw
at the float bowl. (If left in for a long time, the fuel will break down
and could clog the carburetor.)
130 STORAGE
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition key to "OFF". Do not smoke. Make sure the
area is well ventilated and free from any source of flame or sparks; this
includes any appliance with a pilot light.
Gasoline is a toxic substance. Dispose of gasoline properly. Contact your
local authorities for approved disposal methods.
the empty fuel tank, pour about 250 mL (1/2 pint) of motor oil into the
Remove
tank, roll the tank around to coat the inner surfaces thoroughly, and pour out the
excess oil.
the spark plugs and spray fogging oil, such as Kawasaki K-Kare Fogging
Remove
Oil (part number K61030-002), directly into each cylinder. Turn the engine over
several times with the starter button to coat the cylinder walls. Install the spark
plug.
STORAGE 131
WARNING
Do not lean over the engine when performing this procedure. An air/oil
mist may be forcibly ejected from the spark plug hole and could get into
your eyes. if you do get some in your eyes, wash your eyes immediately
with liberal amounts of clean, fresh water. Consult a physician as soon
as possible.
tire pressure by about 20%.
Reduce
Set
the
motorcycle
on a box or stand so that both wheels are raised off the ground.
(If this cannot be done,
put boards under the front and rear wheels to keep damp-
ness away from the tire rubber.)

Spray oil on all unpainted metal surfaces to prevent rusting. Avoid getting oil on
rubber parts or in the brakes.
Lubricate the drive chain and all the cables.
Remove the battery, and store it where it will not be exposed to direct sunlight,
moisture, or freezing temperatures. During storage it should be given a slow
charge (one ampere or less) about once a month. Keep the battery well charged
especially during cold weather.
Tie plastic bags over the muffler to prevent moisture from entering.
Put a cover over the motorcycle to keep dust and dirt from collecting on it.
132 STORAGE
Preparation after Storage:

Remove the plastic bag from the muffler.
Install the battery in the motorcycle and charge the battery if necessary.
Make sure the spark plug is tight.
Fill the fuel tank with fuel.
Check all the points listed in the Daily Safety Checks section.
Lubricate the points listed in the General Lubrication section.
TROUBLESHOOTING GUIDE 133
TROUBLESHOOTING GUIDE
Engine Does Not Start Starter Motor Wont Turn
Engine stop switch off
Clutch lever not pulled in and transmission not in neutral
Fuse blown
Battery leads do not make good electrical contact with battery terminals
Battery discharged
plugs fouled or wet

Spark
Incorrect
spark plug gap
Battery discharged
Engine Cranks, But Wont Start

No fuel in tank
Fuel line clogged
Fuel broken down
Choke is not used when engine is
cold
Engine flooded
Spark plugs not in good contact
is used too long after moving

Choke
off
fuel in tank
No
Fuel
tap is turned off
Fuel tank
air vent is obstructed
Overheating
Battery discharged
Engine Stalls Just When Shifting Into 1st Gear

Side stand has been left down
Clutch does not properly disengage
While Riding
134 OWNER SATISFACTION
OWNER SATISFACTION
(For Products Sold in the Continental United States of America Only)
Your satisfaction is important to your authorized Kawasaki dealer and to Kawasaki
Motors Corp., U.S.A. If you have a problem concerning warranty or service, please
take the following action:
Contact the owner and/or service manager of your authorized Kawasaki dealer.
Fully explain your problem and ask for assistance in resolving the situation. The
OWNER of the dealership is concerned with your satisfaction and your future business. For this reason the owner is in the best position to assist you. Also, all
warranty and service matters are handled and resolved through the authorized
Kawasaki dealer network.
If you are unsatisfied after working with your Kawasaki dealer and feel you still require further assistance, write to the address below. Please be certain to provide
the model, product identification number, mileage or hours of use, accessories,
dates that events occurred and what action has been taken by both you and your
dealer. Include the name and address of the dealership. To assist us in resolving
your inquiry, please include copies of related receipts and any other pertinent information including the names of the dealership personnel with whom you have been
working in the resolution of your problem.
OWNER SATISFACTION 135
Upon receipt of your correspondence we will contact the dealership and work with
them in resolving your problem.
In order to provide a permanent record, all warranty and service resolutions take
place only through written correspondence.
Please send your correspondence to:
CONSUMER RELATIONS
KAWASAKI MOTORS CORP., U.S.A.
P. O. Box 25252
SANTA ANA, CA. 92799-5252
(949) 4605688
136 REPORTING SAFETY DEFECTS
REPORTING SAFETY DEFECTS

(For Products Sold in the Continental United States of America Only)
If you believe that your vehicle has a defect which could cause a crash or could
cause injury or death, you should immediately inform the National Highway Traffic
Safety Administration (NHTSA) in addition to notifying Kawasaki Motors Corporation, U.S.A.
If NHTSA receives similar complaints, it may open an investigation, and if it finds
that a safety defect exists in a group of vehicles, it may order a recall and remedy
campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Kawasaki Motors Corporation, U.S.A.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800
-424-9393 (or 366-0123 in Washington, D.C. area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590. You can also obtain other
information about motor vehicle safety from the Hotline.
ENVIRONMENTAL PROTECTION 137
ENVIRONMENTAL PROTECTION
To protect our environment, properly discard used batteries, tires, engine oil, or
other vehicle components that you might dispose of in the future. Consult your
authorized Kawasaki dealer or local environmental waste agency for their proper
disposal procedures.
138 MAINTENANCE RECORD
MAINTENANCE RECORD
Owner Name.......................................................................................
Address ..............................................................................................
Phone Number ...................................................................................
Engine Number ..................................................................................
Vehicle Number..................................................................................
Selling Dealer Name ..........................................................................
Phone Number ...................................................................................
Warranty Start Date ...........................................................................
Note: Keep this information and a spare key in a secure location.
Date
Odometer
Reading
Maintenance Performed
Dealer Name
Dealer Address
MAINTENANCE RECORD 139
Date
Odometer
Reading
Dealer Name
Dealer Address

Date
Odometer
Reading
Dealer Name
Dealer Address
MAINTENANCE RECORD 141
Date
Odometer
Reading
Dealer Name
Dealer Address

Date
Odometer
Reading
Dealer Name
Dealer Address
LABEL INFORMATION 143
LABEL INFORMATION
(1)
(2)
144 LABEL INFORMATION
(3)
(4)
(5)
(6)
(7)
(8)/(9)
(10)
(11)

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Quick Reference Guide

This Quick Reference Guide will

A Table of Contents is included after

HOW TO RIDE THE MOTORCYCLE

MAINTENANCE AND ADJUSTMENT

Whenever you see the symbols

This note symbol indicates points of

KAWASAKI HEAVY INDUSTRIES, LTD.

Nov. 2008. (1). (S, Ke)

Fuel Tank Cap ..................................

Brake Light Switches........................

2 080 mm (81.89 in.)

780 mm (30.71 in.)

1 190 mm (46.85 in.)

1 375 mm (54.13 in.)

270 mm (10.63 in.)

128 kg (282 lb)

DOHC, single-cylinder, 4-stroke, air-cooled

249 cm (15.2 cu in.)

72.0 61.2 mm (2.83 2.41 in.)

10 BTDC @1 300 r/min (rpm) 30 BTDC @5 750

NGK CR8E or ND U24ESR-N

Forced lubrication (wet sump)

1.5 L (1.6 US qt)

6-speed, return shift

Wet, multi disc

Primary Reduction Ratio

Final Reduction Ratio

Overall Drive Ratio

7.326 (Top gear)

107 mm (4.21 in.)

Specifications subject to change without notice.

12 SERIAL NUMBER LOCATIONS

SERIAL NUMBER LOCATIONS

Left Handlebar Switches

Rear Shock Absorber

32. Brake Fluid Reservoir

Important Break-In Instructions

10. Noise Emission Control Information

warranty. In selecting and using accessories, and in loading the motorcycle,

Parts and Accessories

Because a motorcycle is sensitive to

The following general guidelines have

3. All baggage should be carried as

6. Do not install accessories or carry

designed or installed items can result in an unsafe riding condition.

Speedometer, Odometer/Clock, and

The data is maintained even if the

the TRIP A/B button with the

the ODO/CLOCK button. The

the hour and minute displays start

minute display starts flashing. And

push the ODO/CLOCK button,

the ODO/CLOCK button. Both

the TRIP A/B button momentarily advances the hour or

the TRIP A/B button and hold it

The data is maintained by the back

-up power if the ignition key is turned

: When the headlight is on high

Write your key number here.

Ignition Switch/Steering Lock

Engine on. All electrical

Engine off. All electrical

Steering locked. Engine off.